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United States Patent 2,847,061 CHAIR AND METHOD FOR MAKING SAME HerschelB. Morton, Lincoln, Nebr.

Application March 18, 1955, Serial No. 495,085 1 Claim. (Cl. 155-191)The present invention relates to a chair conformably shaped to fit anindividual and to a method for making the same. i

The primary, object of the present invention is to provide a method formaking a chair in which the portion of the seat and back occupied by anindividual is conformably shaped to fit the back, buttocks, andposterior thighs of such individual.

Another object of the present invention is to provide a method formaking a chair which is simple in execution, and commercially feasible.

A further object of the present invention is to provide a chair forindividuals deformed by reason of injury, arthritis, poliomyelitis, ordue to surgical amputation, and which supports with even pressure theback, buttocks, and posterior thighs of the individual.

A still further object of the present invention is to provide a chairwhich may be constructed with interchangeable seats and backs and whichmay be produced in several sizes and shaped to fit individuals ofvarying stature and which afiords to the occupying individual themaximum amount of comfort and rest consistent with correct posture.

These and other objects and advantages of the present invention will befully apparent from the following description when taken in connectionwith the annexed drawings, in which:

Figure 1 is a view in perspective of a chair frame provided with aseparate seat cushion and a separate back cushion, both filled with airto provide a resilient support.

Figure 2 is a view in perspective showing the seat and back cushion ofthe chair frame of Figure 1 covered with a mesh fabric coated with asettable material.

Figure 3 is a view in perspective showing the fabric web of the assemblyof Figure 2 covered with a sheet of rubber protective material.

Figure 4 is a side view in cross section of the assembly of Figure 3showing in dotted lines the figure of a person seated upon such assemblybefore the settable material has hardened.

Figure 5 is a view in perspective of the assembly of Figure 4 showingthe application of a stiffening material thereto.

Figure 6 is a view in perspective showing the formed impressionseparated from the assembly of Figure 5.

Figure 7 is a view in perspective of a mold having the impression ofFigure 6 incorporated therein, with the moldable material in process ofbeing poured into such mold.

Figure 8 is a view in perspective showing the cast form removed from themold of Figure 7.

Figure 9 is a view in perspective showing the cast form of Figure 8 witha rigid supporting backing applied thereto.

Figure 10 is a view in perspective showing the form of Figure 9 whollyencased in an upholstery fabric.

Figure 11 is a view in perspective showing the assem- 2,847,061 PatentedAug. 12, 1958 bly of Figure 10 with a heading applied to the corneredges of the upholstery fabric.

Figure 12 is a view in position on a chair frame.

Figure 13 is a sectional view taken on the line lit-13 of Figure 12.

In carrying out the method of making a chair having a seat and backconformably shaped to fit the back, buttocks and posterior thighs of anindividual, an impression of the back, buttocks and posterior thighs ofan individual is first formed. This is done by providing, Figure l, achair frame 16 having a flexible seat cushion 14 and a flexible backcushion 15, both preferably air filled and with the seat cushion 14under appreciably more air pressure than the back cushion 15. The seatcushion 14 and the back cushion 15 are arranged in whatever position isdesired in the finished chair, in an erect position if an office chairis to be constructed, for instance, or more or less in a recliningposition if a reclining chair is to be constructed.

A coating of a settable impression forming material is next applied tothe seat cushion 14 and and the back cushion 15. This is done byapplying a web of mesh fabric 17 impregnated with the impression formingmaterial, such as plaster of Paris, to the portion of the seat cushion14 and the back cushion 15 occupied by a seated individual, as shown inFigure 2, whereupon a flexible waterproof sheet 18 of rubber, or thelike, is immediately stretched over the impregnated fabric web whilestill in its unset stage, as seen in Figure 3.

An individual whose impression is desired is then seated upon the sheet18 as shown in Figure 4 in dotted lines and indicated by the referencenumeral 19, and such individual is permitted to remain so seated untilthe plastic material in the impregnated mesh fabric 17 has set orhardened. At this point the individual arises from the sitting postureof Figure 4, and the rubber sheeet l8 promptly removed. Next, a layer ofplastic settable at room temperature in a liquid state is applied to theimpression containing fabric 17 in quantity to form a rigid impressionof the desired thickness, as by spraying indicated by the numeral 20 inFigure 5. After the plastic has set, the thus formed impression isremoved from the chair frame 16, Figure 5, such formed impression beingindicated by the reference numeral 21, Fig ure 6.

From the thus formed impression 21, Figure 6, a flexible casting is nextformed. This is effected by forming a seat and back mold 22, Figure 7,having the impression 21 incorporated in the front face thereof. Intothe mold 22 is poured a flexible material, such as foam rubber 23 in aliquid uncured state, as also shown in Figure 7, in quantity sufficientto fill the mold, and the mold then subjected to a curing treatment.When the foam rubber has been cured, the thus formed casting is removedfrom the mold 22, the casting being shown in Figure 8 and indicated bythe reference numeral 24. It is to be noted that the front face of thecasting 24 has the shaping of the impression 21, namely, a shapingconformably shaped to fit the back, buttocks, and posterior thighs ofthe individual 19. To the casting 24 is next applied a rigid supportingbacking 25 which may be either of metal, wood, or like rigid material,as shown in Figure 9 to form a seat and back assembly. The seat and backassembly of Figure 9 is then totally encased in a sheet of upholsteringfabric 26, as shown in Figure 10, and suitable edging or trim 27 isapplied to the corners of the fabric 26, as shown in Figure 11'. Theencased seat and back assembly is then mounted in a chair frame 28, asshown in Figures 12 and 13 and here shown to be constructed of tubes orsolid metal rods and bars fabricated of such materials as aluminum,magnesium, wrought iron, steel, or the like.

The foam rubber seat and back assembly thus formed by the method of thepresent invention as seen in Figure 12 has depressions 29, 30 and 31conformably shaped to fit the posterior thighs,'buttocks, and the back,respectively, of the individual and providing points of equal pressurebetween such portions of the body so as to result in a comfortable chairgiving perfect posture to the body of such individual.

In the case of individuals deformed by disease, surgery, or due to otherconditions, the seat and back assembly of the present invention mayprovide such support to the individual as will permit him to engage inhis normal occupation.

It is contemplated that the seat and back assembly of the presentinvention may be made in a variety of shapes and sizes, and may beinterchangeably mounted within the chair frame 28, permitting economicalmanufacture and sale of perfectly contoured chairs conformably shaped toseveral sizes of persons of various statutes.

In place of forming a casting of the impression 21, a layer of flexiblematerial may be applied to the front face of the impression. the layerbeing applied in a thickness such to give the resultant impressionflexibility without destroying or altering the formed shaping in thefront face of the impression. The layer of flexible material may be madeof foam rubber or any like material giving flexibility to the impressionwhen applied thereto. The impression may then be totally incased in theupholstering fabric 26. suitable edging or trim 27 applied to thecorners of such fabric, and thence mounting in a chair frame 28.

If desired, the impression 21 may be employed without further treatmentas a seat and back for a chair.

What is claimed is:

A chair comprising a frame including a seat and a back, and a one-piecefoam rubber casting fltted in said frame and including a seat portionsupported on the frame seat and a back portion supported against theframe back. the front of said one-piece foam rubber casting havingformed therein a single continuous impression, said impressionconforming to the shape of a person's back, buttocks, and posteriorthighs, the thickness of said foam rubber casting throughout its entireextent being sufficient to give full, comfortable support to the back,buttocks and posterior thighs of a person seated in said chair.

References Cited in the flle of this patent UNITED STATES PATENTS D.142,800 Watson Nov. 6, 1945 672,193 McKinley Apr. 16, 1901 1,716,871Weldon June ll, 1929 1,917,264 Kellogg July ll, 1933 2,251,318 Reynoldset al. Aug. 5, 1941 2,259,534 Blair et al. Oct. 21, 1941 2,542,931Lightfoot Feb. 20, 1951 2,565,758 Covino Aug. 28, 1951

